Optical arrangement in machine vision system with diffusive and direct illumination for dpm indicia

ABSTRACT

An apparatus for capturing an image of at least one object appearing in an imaging field of view (FOV). A housing has an imaging sensor operably coupled with the circuit board, the imaging sensor configured to capture an image frame appearing in the imaging FOV and defining an imaging axis. An illumination assembly has a plurality of light sources operably coupled with the circuit board, a diffuser positioned adjacent to the plurality of light sources, the diffuser configured to generate a diffused light pattern, and a light pipe positioned adjacent to the plurality of light sources to generate a direct illumination pattern and an off-axis illumination pattern, wherein the direct illumination pattern is oriented generally parallel to the imaging axis and the off-axis illumination pattern is configured to intersect the imaging axis.

BACKGROUND

Barcode and other scanning devices generally capture images within agiven field of view (FOV). Barcode readers may be provided to be used atvarious fields of view and various distances from a target object.Typically, different distances and fields of view require differentdesign requirements such as different intensities and types ofillumination. In particular, reading direct part marking (DPM) barcodesrequires diffusive illumination and, in some scenarios, off-axisillumination depending on the substrate that the DPM barcode is printedon. Systems may require greater illumination, or focused illumination,for objects at distances of 12 inches or further, compared to typicalbarcode scanning devices.

Typical barcode scanning illumination systems do not provide theversatility required to effectively read DPM barcodes that are printedon a wide variety of substrates, and at different distances. Thediffering design requirements oftentimes require different housing andcomponent locations, different illumination sources, as well asadditional components such as mirrors, lenses, and printed circuitboards.

Accordingly, there is a need for improved systems and/or accessorieshaving improved functionalities.

SUMMARY

In an embodiment, an optical assembly is provided for capturing at leastone image of an object appearing in an imaging field of view (FOV). Theoptical assembly comprises a circuit board, an imaging sensor operablycoupled with the circuit board, and an illumination assembly. Theimaging sensor is configured to capture an image frame appearing in theimaging FOV and additionally defines an imaging axis. The illuminationassembly includes a plurality of light sources operably coupled with thecircuit board, a diffuser positioned adjacent to the plurality of lightsources, and a first light pipe positioned adjacent to the plurality oflight sources. The plurality of light sources are configured to emitlight to illuminate the object. The diffuser is configured to generate adiffused light pattern. The first light pipe is configured to generate adirect illumination pattern and an off-axis illumination pattern. Thedirect illumination pattern is oriented generally parallel to theimaging axis and the off-axis illumination pattern is configured tointersect the imaging axis.

In a variation of the current embodiment, the first light pipe includesa body having a first end and a second end and defining a longitudinallight pipe axis, an input surface positioned at the first end of thebody, and an exit surface positioned at the second end of the body. Theinput surface is configured to be positioned adjacent to, and to receivethe emitted light from, the plurality of light sources. The exit surfaceextends across a width of the first light pipe and includes a first exitsurface portion and a second exit surface portion. The first exitsurface portion is oriented generally perpendicular to the imaging axisand the second exit surface portion is oriented at an angle greater thanapproximately 85° relative to the imaging axis. The longitudinal lightpipe axis of the body of the first light pipe is configured to beparallel to the imaging axis and wherein the exit surface is configuredto direct the emitted light towards the object.

In some approaches, the input surface has a positive optical power. Inthese and other examples, the exit surface has a negative optical power.The input surface may include a plurality of converging lenses. Further,in some variations, the exit surface includes a first exit surfaceportion having a concave surface and a second exit surface portionhaving a convex surface being positioned adjacent to the first exitsurface portion. The second exit surface portion may define a wedge.

In embodiments, the diffuser includes a diffusing body and a flangeportion surrounding the diffusing body. The diffusing body may have acentral region defining an opening dimensioned to be at least equal tothe imaging FOV, and the central region extending from a first height toa second height to define a curved wall corresponding to the imagingFOV. The flange portion may include an opening configured to receive aportion of the first light pipe. In some forms, the first light pipefurther includes a mounting member configured to operably couple thefirst light pipe with the diffuser.

In some examples, the imaging FOV includes an imaging FOV width and animaging FOV height. The width of the first light pipe is configured tobe positioned parallel to the imaging FOV width along the flange portionof the diffuser. In these and other examples, the assembly may furtherinclude a second light pipe positioned on the flange portion of thediffuser opposite the first light pipe.

In some approaches, the assembly may include eight optical sources toprovide optical energy to the diffuser to generate diffuse illuminationof the object, and at least two optical sources configured to provideoptical energy to the light pipe to generate direct and indirectillumination of the object.

In accordance with a second aspect, a light pipe for use with a barcodereader having an illumination assembly configured to illuminate at leastone object to be captured by an imaging assembly is provided. The lightpipe includes a body having a first end and a second end and defining alongitudinal light pipe axis, an input surface positioned at the firstend of the body, and an exit surface positioned at the second end of thebody. The input surface is positioned adjacent to and receives emittedlight from an illumination source of the imaging assembly. The exitsurface includes a first exit surface portion and a second exit surfaceportion. The first exit surface portion is oriented generallyperpendicular to the longitudinal light pipe axis and the second exitsurface portion is oriented at an angle greater than approximately 85°relative to the longitudinal light pipe axis. The exit surface isconfigured to direct the emitted light towards the object. The body isconfigured to generate a direct illumination pattern and an off-axisillumination pattern at the exit surface, wherein the directillumination pattern exits the exit surface at the first exit surfaceportion and the off-axis illumination pattern exits the exit surface atthe second exit surface portion.

In accordance with a third aspect, a removable light directing assemblyfor use with an illumination assembly for illuminating at least oneobject to be captured by an imaging assembly is provided. The removablelight directing assembly includes a first light pipe positionableadjacent to an illumination assembly to receive emitted light therefromand a diffuser operably coupled with the first light pipe and beingpositionable adjacent to the illumination assembly. The first light pipeincludes a body having a first end and a second end and defining alongitudinal light pipe axis. The first light pipe generates a directillumination pattern oriented generally parallel to the longitudinallight pipe axis and an off-axis illumination pattern oriented at anangle greater than approximately 5° relative to the longitudinal lightpipe axis. The diffuser generates a diffused light pattern.

In accordance with a fourth aspect, a light pipe is provided for use ina barcode reader having an illumination assembly configured toilluminate at least one object to be captured by an imaging assembly.The light pipe includes a first end having a plurality of convex inputsurfaces, a second end having an exit surface and a flange extendingaround the exit surface, and a central portion extending between thefirst end and the second end and defining a longitudinal light pipeaxis. The exit surface extends across a width of the second end anddefines a trough portion and a wedge portion. The exit surface iscontoured such that a first portion of light received by the pluralityof convex input surfaces exits at the exit surface in a directiongenerally parallel to the longitudinal light pipe axis and a secondportion of light received by the plurality of convex input surfacesexits at the exit surface in a direction greater than approximately 5°relative to the longitudinal light pipe axis.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The accompanying figures, where like reference numerals refer toidentical or functionally similar elements throughout the separateviews, together with the detailed description below, are incorporated inand form part of the specification, and serve to further illustrateembodiments of concepts that include the claimed invention, and explainvarious principles and advantages of those embodiments.

FIG. 1 illustrates a block diagram of an imaging-based machine visiondevice in accordance with this disclosure.

FIG. 2A is a side perspective cross sectional view of a machine visiondevice in accordance with this disclosure.

FIG. 2B is a side cross sectional view of the machine vision device ofFIG. 2A in accordance with this disclosure.

FIG. 2C is a top view of the machine vision device of FIG. 2A inaccordance with this disclosure.

FIG. 3A is a perspective cut away view of an embodiment of a diffuserfor an imaging-based machine vision device in accordance with thisdisclosure.

FIG. 3B is a perspective cut away view of an embodiment of a diffuserfor an imaging-based machine vision device in accordance with thisdisclosure.

FIG. 4A is a perspective view of an embodiment of a light pipe for usein an illumination system in a machine vision device in accordance withthis disclosure.

FIG. 4B is a perspective view of an embodiment of a light pipe for usein an illumination system in a machine vision device in accordance withthis disclosure.

FIG. 4C illustrates a mechanical model of an embodiment of a light pipein accordance with this disclosure.

FIG. 5A is a top view of a ray trace diagrams of rays of lightpropagating through a light pipe in accordance with this disclosure.

FIG. 5B is a side view of a ray trace diagrams of rays of lightpropagating through a light pipe in accordance with this disclosure.

FIG. 6 is an illustration of an embodiment of a light pipe havingadditional features for implementation of a machine vision device inaccordance with this disclosure.

FIG. 7A is a perspective view of a light pipe physically coupled to aframe for implementation in a machine vision device in accordance withthis disclosure.

FIG. 7B is a perspective view of a light pipe physically coupled to aframe for implementation in a machine vision device in accordance withthis disclosure.

FIG. 7C is a perspective view of a light pipe physically coupled to aframe for implementation in a machine vision device in accordance withthis disclosure.

FIG. 8 is top perspective view of an embodiment on an illuminationcircuit board for use in an illumination system for a machine visiondevice in accordance with this disclosure.

Skilled artisans will appreciate that elements in the figures areillustrated for simplicity and clarity and have not necessarily beendrawn to scale. For example, the dimensions of some of the elements inthe figures may be exaggerated relative to other elements to help toimprove understanding of embodiments of the present invention.

The apparatus and method components have been represented whereappropriate by conventional symbols in the drawings, showing only thosespecific details that are pertinent to understanding the embodiments ofthe present invention so as not to obscure the disclosure with detailsthat will be readily apparent to those of ordinary skill in the arthaving the benefit of the description herein.

DETAILED DESCRIPTION

Portable high-performance optical imaging systems for machine visionemploy small imaging sensors to maintain small form factors. Forexample, a typical machine vision imaging sensor has an imaging sensorrectangular area of around 6 by 6 millimeters with sensor pixels areasof approximately 3 microns. Some high-performance compact machine visionsystems require wide-angle fields of view (FOVs) (e.g., greater than 40degrees) in addition to small form factor imaging sensors. Differentfields of view and distances of target objects for imaging requiredifferent intensities and types of illumination. Machine vision systemsfor imaging direct part marking (DPM) barcodes require diffusiveillumination and, in some scenarios, off-axis illumination depending onthe substrate that the DPM barcode is printed on. Systems may requiregreater illumination, or focused illumination, for objects at distancesof 12 inches or further, compared to typical barcode scanning devices.The current disclosure describes a machine vision system that employs anillumination system that includes a diffuser and a light pipe thatprovide three types of illumination: (i) diffuse illumination, (ii)direct illumination, and (iii) indirect illumination, to a targetobject. The described machine vision system allows for robustmeasurements of multiple types of barcodes, and DPM barcodes, at a rangeof distances.

In an implementation, the present application provides an assembly forcapturing at least one image of an object appearing in an imaging fieldof view (FOV). In various embodiments of the present disclosure theassembly includes a circuit board and an imaging sensor operably coupledwith the circuit board, the imaging sensor configured to capture animage frame appearing in the imaging FOV and defining an imaging axis.The assembly further includes an illumination assembly having aplurality of light sources operably coupled with the circuit board, withthe plurality of light sources configured to emit light to illuminatethe object. The illumination assembly further includes a diffuserpositioned adjacent to the plurality of light sources, the diffuserconfigured to generate a diffused light pattern; and a first light pipepositioned adjacent to the plurality of light sources to generate adirect illumination pattern and an off-axis illumination pattern,wherein the direct illumination pattern is oriented generally parallelto the imaging axis and the off-axis illumination pattern is configuredto intersect the imaging axis. The diffuser and the first light pipe maycooperate to form a removable light directing assembly.

In implementations, the first light pipe includes a body having a firstend and a second end and defining a longitudinal light pipe axis. Thefirst light pipe further includes an input surface positioned at thefirst end of the body, the input surface configured to be positionedadjacent to, and to receive the emitted light from, the plurality oflight sources. The first light pipe also has an exit surface positionedat the second end of the body extending across a width of the firstlight pipe, the exit surface including a first exit surface portion anda second exit surface portion, the first exit surface portion beingoriented generally perpendicular to the imaging axis and the second exitsurface portion being oriented at an angle greater than approximately85° relative to the imaging axis. The longitudinal light pipe axis ofthe body of the first light pipe is configured to be parallel to theimaging axis and the exit surface is configured to direct the emittedlight towards the object.

Turning to the figures, FIG. 1 illustrates a block diagram of animaging-based machine vision device 100. The machine vision device 100may be a direct part marking (DPM) barcode reader device, andaccordingly, these terms may be used interchangeably herein. The device100 includes a housing 102, an illumination assembly 106, an imagingassembly 110 disposed within the housing 102, and a sensor assembly 114.The illumination assembly 106 includes light sources, waveguides, anddiffusers configured to provide for direct and indirect illumination ofa target object. The imaging assembly 110 includes optics such aslenses, apertures, and other optics for imaging an image of the targetobject onto an imaging sensor. The sensor assembly 114 includes animaging sensor (e.g., a photodiode array, CCD camera, etc.) andcircuitry for receiving an image of the target object and generating anelectrical signal indicative of the target object. In embodiments, theillumination assembly 106 may not be housed within the housing 102, andthe illumination assembly 106 may be removable or detachable from theimaging assembly 106 and the sensor assembly 114.

Referring now simultaneously to FIG. 1 and FIGS. 2A-2C. FIG. 2A is aside perspective cross sectional view of the machine vision device 100of FIG. 1, FIG. 2B is a side cross sectional view of the machine visiondevice 100 of FIG. 1, and FIG. 2C is a top view of the machine visiondevice 100 of FIG. 1. The illumination assembly 106 of the machinevision device 100 includes a diffuser 120, one or more light pipes 123,a plurality of optical sources 126, and an illumination circuit board128 for capturing an image of a target object 136 inside of a field ofview 139 of the machine vision device 100. A portion of the plurality ofoptical sources 126 are configured to provide optical energy to thelight pipes 123, while another portion of the plurality of the opticallight sources are configured to provide optical energy to the diffuser120. In embodiments, the optical sources 126 may include one or more ofa light emitting diode, organic light emitting diode, laser diode, blackbody radiation source, ultraviolet radiation source, infrared radiationsource, or another illumination source. In embodiments, the majority ofthe optical energy provided to the light pipes 123 and the diffuser 120is provided in a manner such that the majority of the optical energypropagates through the light pipes 123 and diffuser 120, as described inmore detail further herein. The diffuser 120 is configured to providediffuse illumination (illustrated by arrows having reference numeral130) to illuminate the target object 136 within the field of view 139 ofthe machine vision device 100. The light pipes 123 are opticalwaveguides configured to provide direct illumination 132 and off-axisillumination 133 to the target object 136. The illumination circuitboard 128 is in electrical communication with the optical sources 126 tocontrol the emission of optical energy from the optical sources toprovide illumination to the target 136. For example, in embodiments, acontroller may be in electrical communication with the optical sources126 through busses or electrical lines of the illumination circuit board128 to control the optical sources 126. In embodiments, the controllermay be an external controller in electrical communication with theillumination circuit board 128 to control the optical sources 126, orthe controller may be mounted directly on the illumination circuit board128, such as alongside the optical sources 128, or on an underside, orside opposite the optical sources 126, of the illumination circuit board128.

The imaging assembly 110 includes optical elements for imaging thetarget object 136 onto an image sensor 145 of the sensor assembly 114.In embodiments, the imaging assembly includes one or more asphericlenses, glass lenses, variable focus lenses, spatial filters, opticalfilters, apertures, bandpass filters, highpass filters, lowpass filters,notch filters, chromatic filters, neutral density filters, or anothertype of lens or optical element. In embodiments, the imaging assemblymay be configured to correct or mitigate chromatic dispersion, opticalfield curvature, coma, chromatic aberrations, and/or other optical fielddistortions. In any embodiments, the imaging assembly 110 is configuredto allow for the image of the target object 136 to form correctly on theimaging sensor 145. Other configurations and/or components may be used.

The sensor assembly 114 includes an imaging sensor 145 and a sensorcircuit board 147. The imaging sensor 145 is configured to receive animage of the target object 136 and to generate an electrical signalindicative of the image of the target object 136. The sensor circuitboard 147 is communicatively coupled to the imaging sensor 145 tocontrol the imaging sensor 145 for obtaining an image of the targetobject 136. The sensor circuit board 147 may include additionalcomponents such as a controller for controlling when to active theimaging sensor 145 to capture the image (i.e., an image frame) of thetarget object 136. Additionally, the sensor circuit board 147 mayinclude one or more memories for storing the electrical signalindicative of the captured image, or for storing computer readableinstructions for controlling the imaging sensor 145. Additionally,sensor circuit board may have input/output ports or otherwise be incommunication with the illumination circuit board 128 to control theplurality optical sources 126. By controlling both the optical sources126 and the imaging sensor 145, the plurality of optical sources 126, ora subset of the plurality of optical sources 126, may be activated onlywhile the imaging sensor 145 is active, which may preserve energy andallow for lower power requirements for operation of the device 100. Thesensor circuit board may include a communications module or input/outputdevices and ports for communicating with external systems, devices, andnetworks.

The imaging sensor 145 may have a plurality of photosensitive elementsforming a substantially flat surface and may be fixedly mounted relativeto the housing 102 using any number of components and/or approaches. Theimage sensor 112 further has a defined central imaging axis A that isnormal to the substantially flat surface on a detection surface of theimaging sensor112, with the detection surface being approximately at theimaging plane of the imaging assembly 110. In some embodiments, theimaging axis is coaxial with a central axis of the imaging assembly 110.The imaging assembly 110 may also be fixedly mounted relative to thehousing 102 using any number of components and/or approaches. In theillustrated embodiment, the imaging assembly 110 is positioned betweenthe illumination assembly 106 and the image sensor 112. The imagingassembly 110 may include one or more apertures to block light fromobjects outside of the field of view, which reduces imaging problems dueto stray light from objects other than the target object. Additionally,the illumination circuit board 128 may include an aperture to reducelight from the optical sources 126 from entering the imaging assembly110, and/or the imaging sensor 145. As described herein, directillumination may be considered optical energy or illuminationpropagating substantially parallel to the imaging axis, and indirectillumination, or off-axis illumination, may be considered to be anyoptical energy propagating in a direction that intersects with theimaging axis.

The machine vision device 100 has an imaging field of view (FOV) forcapturing image frames of the target object 136. The FOV has an FOVwidth FOVw, and an FOV height FOVh, illustrated in FIG. 2C, defined bythe size of the sensor, optics of the illumination assembly 106, and anyapertures along the imaging axis A.

In embodiments, the machine vision device 100 may include additionalelements, or may be adapted to be inserted into a docking station withadditional elements such as an AC power source to provide power for themachine vision device 100, or another computational device, externalnetwork, or communications module for communicating between the machinevision device 100 and external devices and systems. The machine visiondevice 100 may further include an onboard power supply such as a batteryconfigured to supply power to the illumination circuit board 128 and thesensor circuit board 147. Additionally, the machine vision device 100may include a memory and a controller that controls operation of theimaging system 110 (e.g., the optical sources 126 and the imaging sensor145). In embodiments, the machine vision device 100 may include atrigger (not shown in the illustration) that is used to activate thedevice to capture an image. The machine vision device 100 may includeany number of additional components such as decoding systems,processors, and/or circuitry coupled to the illumination circuit board128, the sensor circuit board 147, and/or any other circuitry andcircuit boards to assist in operation of the device 100.

FIGS. 3A and 3B are perspective cut away view of an embodiment of aremovable light directing assembly 150 which includes the diffuser 120and the light pipe 123 of FIGS. 2A-2C. The diffuser 120 may include adiffusing body 152 and a flange portion 165. In the illustrated example,the diffusing body 152 includes four curved surfaces 154 a, 154 b, 154 c(the fourth surface is not illustrated, but is to be understood to beincluded in discussions of the surfaces of the diffuser) that are inphysical contact and cooperate to form a central region 153. The curvedsurfaces 154 a-154 c extend from a first height 156 (FIG. 3B) to asecond height 158 (FIG. 3B) to form a wider aperture at the secondheight 158, and a narrower aperture 160 at the first height 156. Putdifferently, the wide aperture is positioned at a location away ordistally from the imaging sensor 145 and the narrow aperture 160 ispositioned at a location near or distally to the imaging sensor 145compared to the wide aperture. The narrow aperture 160 may assist inreducing the amount of stray light that is received by the imagingsensor 145. Additionally, the narrow aperture may define the imaging FOVof the imaging sensor and machine vision system. The curvature of thesurfaces 154 a-154 c of the diffuser 120 provide a substantially uniformlight distribution for illumination of the target object 136. Inembodiments, the curvature of the surfaces is generally cylindrical inshape with a radius of curvature of approximately 22.5 millimeters.

The diffuser 120 may be constructed from a plastic material, a glassmaterial, a plastic polycarbonate, an acrylic material, or an otherwisetransparent material for light from a subset of the plurality of opticalsource 126 to propagate therethrough. In embodiments, the diffuser 120is constructed from a semi-transparent diffusive white plastic materialand the light sources 126 are light emitting diodes (LEDs). Inembodiments, the light sources 126 are approximately 23 millimeters fromthe closest segment of the surface of the diffuser 120. Configuring thelight sources 126 to be positioned at substantially the same distancefrom the entire surface of the nearest surface of the diffuser 120yields a more uniform illuminance of the diffuser surface, which furthergenerates a more uniform luminance of the surface itself forilluminating the target object 136. In embodiments, the diffuser 120 mayhave roughened surfaces for dispersing, or diffusing light, for examplethere may be microlenses on the surfaces of the diffuser 120 fordiffusing light. Additionally, the diffuser 120 may include diffusiveelements within the surfaces of the diffuser 120 such as microbeads,small pockets of air, or another aberration configured to disperse anddiffuse optical energy propagating through the diffuser 120. In anyembodiment, the diffuser 120 is configured to receive light from asubset of the plurality of optical sources 126, diffuse the receivedlight, and to provide diffuse illumination to the target object 136.Additionally, in embodiments, the diffuser 120 is configured such thatlight reflected by the target object 136 propagates through the wide andnarrow aperture of the diffuser 120 and into the imaging assembly 110 tobe received by the imaging sensor 145. The arrangement of the diffuser120 relative to the positioning of the plurality of optical sources 126aids in generating a substantially uniform illumination of the targetobject 136 and minimizes the formation of optical “hot spots”.

The flange portion 165 of the diffuser 120 is a substantially flat, orslightly curved, portion having an opening 167 configured to receive aportion of the light pipe 123 therethrough. The flange portion 165 mayhold one or more light pipes 123 in a position configured for the lightpipes 123 to receive light from optical sources. In embodiments, theopening 167 may be configured such that the width of a light pipe 123positioned in the opening is parallel to the FOV width FOVw, asillustrated in FIG. 2C. In embodiments, the flange portion 165 mayinclude any number of openings such as, for example, one opening 167,two openings 167, or three or more openings 167each of which beingconfigured to receive a portion of one or more light pipes 123. Asillustrated in FIG. 2C, and throughout this specification, a secondlight 123 pipe may be positioned in a flange portion 165 b opposite thefirst light pipe 123 in an opposite flange portion 165 a in the diffuser120.

FIGS. 4A and 4B are perspective views of an embodiment of the light pipe123. The light pipe 123 has first and second input surfaces 202 at afirst end 123 a of the light pipe 123, a pipe region 204, and an exitsurface 207 at a second end 123 b of the light pipe 123. The pipe region204 may also be referred to as the body of the light pipe 123 extendingbetween the first and second surfaces 202 and 207, respectively at thefirst and second ends of the light pipe 123. Additionally, the lightpipe 123 has a longitudinal light pipe axis B that extends along thelength of the body 204 from the first end 123 a of the light pipe 123 tothe second end 123 b thereof. Additionally, the light pipe 123 has alight pipe width 208. Light from optical sources, such as the opticalsources 126 of FIGS. 2A-2C, enters the light pipe 123 through the inputsurfaces 202. In the illustrated example, the first and second inputsurfaces 202 have positive optical power, and a free form shape. Inembodiments, the first and second input surfaces 202 may each be in theform of a surface having a positive curvature, or a lens withsubstantially positive optical power.

The exit surface 207 has a substantially cylindrical shape and includestwo surface portions (discussed in further detail below), with one ofthe surface portions having an aspherical shape with a negative opticalpower, and the other surface portion being substantially flat. Inembodiments, the exit surface 207 has an overall negative optical power.In the illustrated example, the curvature vertex of the exit surface 207is offset from the center axis of the pipe region 204. In embodiments,the curvature vertex of the exit surface 207 is 2.4 mm off axis from thecenter of the light pipe 200. The exit surface 207 may further include awedge to redirect a portion of the light toward the imaging axis of theimaging sensor 145 providing the off-axis indirect illumination 212. Inembodiments, the exit surface 207, input surfaces 202, and/or sidesurfaces of the pipe region 204 may be textured of have diffuserelements to assist in scattering the light in preferred directions(i.e., toward the imaging axis of the imaging sensor 145). The piperegion 204 may be constructed from any plastic, glass, acrylic, or othermaterial capable of passing or transmitting greater than approximately50% of the light entering the input surfaces 202 to the output surface207. In embodiments, the light pipe 123 is configured to transmitthrough the exit surface 207 at least approximately 95% of the lightreceived at the input surfaces 202. As such, the pipe region 204 is anoptical waveguide. The pipe region 204 is substantially rectangular withtapered sides, and the pipe region 204 guides the light through totalinternal reflection.

The pipe region 204 may be a substantially light transparent material,which, in embodiments, may include glass, plastic, an acrylic material,or another material having an index of refraction, and geometry,configured to guide light from the input surfaces 202 to the exitsurface 207. Light exiting the exit surface 207 is emitted in twodirections and/or patterns: a direct illumination pattern 210 is emittedsubstantially forward out of the light pipe 123 along the length axis ofthe pipe region 204, and an indirect illumination pattern 212 is emittedat an off-axis angle towards the imaging axis of the imaging sensor 145to provide off-axis illumination. The direct illumination 210 may beuseful for illuminating a target object that is at distances greaterthan approximately 5 or 6 inches from the imaging sensor 145, and mayenable imaging of an object at distances of greater than 12 inches,while the indirect illumination 212 may be useful for illuminatingtarget objects at distances of 6 inches or less from the imaging sensor145. In embodiments, the pipe region 204 may be any optical waveguideconfigured to guide, transmit, or pass light from the first end 123 a ofthe light pipe 123 to the second end 123 b of the light pipe 123.

FIG. 4C illustrates a mechanical model of an embodiment of the lightpipe 123 having input surface 202, pipe region 204, and exit surface207. Notably, the exit surface 207 has a first exit portion 207 a and asecond exit portion 207 b. The first exit portion 207 a is generallyperpendicular to the light pipe axis B, is a concave, substantiallycylindrical surface and has a radius of curvature 209 a. In embodiments,the radius of curvature of the first exit portion 207 a is approximately13.3 millimeters. Other examples are possible. The concave first exitportion 207 a may be considered a trough portion. As illustrated in FIG.4C, the curvature of the first exit surface portion 207 a is notcentered on, or is off-axis from, the light pipe axis B, however, inother examples, the curvature of the first exit surface portion 207 amay be centered on the light pipe axis B. In embodiments, the first exitsurface portion 207 a is configured to transmit at least approximately40% of the light received at the input surface 202.

In embodiments, the second exit surface portion 207 b is convex and isoriented at an angle of approximately greater than 85° relative to thelongitudinal light pipe axis B and creates a wedge to assist ingenerating the off-axis illumination for illuminating a target object.In embodiments, the second exit surface portion 207 b is configured totransmit at least approximately 40% of the light received at the inputsurface 202. Together, the first exit surface portion 207 a and thesecond exit surface portion 207 b cause the light to exit the exitsurface 207 as both direct illumination for illuminating target objectsfarther than approximately 6 inches, and indirect illumination forilluminating target objects at distances of 6 inches or less.Additionally, the off-axis indirect illumination enables a barcodereader or machine vision system to better image DPM barcodes and/ormarkings. In embodiments, the input surface 202 may have an overallpositive optical power, and the input surface 202 may include one ormore converging lenses.

FIGS. 5A and 5B are ray trace diagrams of rays of light propagatingthrough the light pipe 123. Two optical sources 126 provide light to thefirst and second input surfaces 202. The input surfaces 202 are curvedto provide focusing of the light into the pipe region 204 of the lightpipe 123. The optical sources 126 are placed at a distance and locationconfigured to focus the majority of the light emitted by the opticalsources 126 into the light pipe 123. As illustrated in FIGS. 5A and 5B,the majority of the light that enters the light pipe 123 is contained bythe light pipe body, or pipe region 204, and is totally internallyreflected within the surfaces of the light pipe 123. The light is thenemitted from the exit surface 207 as direct illumination 210 andindirect illumination 212, as described herein.

With reference to FIG. 6, the light pipe 123 can additionally include amounting member illustrated as a locating pin 214 and lock-in wedges 216protruding from the light pipe 123. The locating pin 214 (i.e., amounting member) fits into a corresponding mounting member, which may bein the form of a notch or opening in a housing and/or a diffuser, suchas the housing 102 or diffuser 120. In embodiments, the locating pin 214may physically couple to a mounting member in part fixedly attached tothe housing 102 or diffuser 120. The locating pin 214 and notch ensurethat the light pipe 123 is positioned relative to optical light sourcesto ensure efficient coupling of light from the optical light sourcesinto the light pipe 123 through the input surfaces 202. The lock-inwedges 216 protrude from the sides of the light pipe 123 and areconfigured to clip onto or otherwise secure with a frame or lightblocking shield, to prevent stray light from entering the light pipe123, discussed further in reference to FIGS. 7A-7C.

FIGS. 7A-7C are perspective views of the light pipe 123 being coupledwith a frame 450 for implementation in a machine vision device, such asthe machine vision device 100. In embodiments, the frame 450 includes aback panel 452, and a first and second side panel 454 a and 454 b, and alatch 457. The back panel 452 acts as an isolating shield, isolatingshield member, or light blocking preventing light from undesirableoptical sources from entering the light pipe 123. In embodiments, theentire frame 450, or the back panel 452 of the frame 450, may be ametal, a cloudy or opaque plastic, an opaque glass, a syntheticmaterial, or another opaque material capable of blocking stray lightfrom reaching the light pipe 123 and entering into the light pipe 123.In embodiments, as FIG. 7B illustrates, the frame 450 may be physicallycoupled with the light pipe 123 with the frame 450 clipping to, snappingonto, or otherwise attaching to the light pipe. The light pipe 123 andframe 4550 may then be inserted into the diffuser 120 as illustrated inFIGS. 7B, and 7C. In embodiments, the light pipe 123 may be physicallycoupled to the diffuser 120 before the frame 450 is physically attachedto the light pipe 123. For example, the light pipe 123 may be physicallycoupled to the diffuser 120 by two shot molding, an adhesive, a tape, oranother coupling method. The light pipe 123, frame 450, and diffuser 120may then be positioned by the locating pin 214, as previously describedin reference to FIG. 6, to be physically configured relative to anoptical source 126 a to receive light from the optical source 126 athrough input surfaces 202, and for the diffuser 120 to receive lightfrom the optical sources 126 b, as further described in reference toFIG. 8. The light may then propagate through the pipe region 204 of thelight pipe 123, and exit the light pipe 123 through the exit surface207. The back panel 452 may be positioned between the light pipe 123 andthe nearby diffuser to prevent light from the optical source 126 a fromreaching the nearby diffuser 120. Additionally, a nearby second opticalsource 126 b may provide light to the nearby diffuser 120, and the backpanel 452 may prevent light from the second optical source 126 b fromreaching the light pipe 123. In embodiments, the light pipe 123 isphysically positioned by the locating pin 214, coupled with the diffuser120. For example, in embodiments, the locating pin 214 may snap into, orfit into a crevice of the diffuser 120 to hold the location pin 214, andtherefore light pipe 123 and frame 450, in a desired location relativeto the illumination circuit board 128 and optical sources 126.

In embodiments, the frame 450 may be physically secured to the lightpipe 123 by one or more wedges 216 of the light pipe 123. The one ormore wedges 216 may latch, or snap fit, onto the first and/or secondside panel 454 a and 454 b to secure the frame 450 into place. The sidepanels 454 a and 454 b may be resiliently flexible such that they maybend as frame 450 is being attached to the light pipe 123. Inembodiments, the diffuser 120 and the locating pin 214 position thelight pipe 123 at a distance 418 from an outer wall of the diffuser 120.The distance 418 allows for an air layer to be present between the lightpipe 123 and the diffuser 120 to prevent light from leaking out of thelight pipe 123 into the diffuser 120. The amount of light leakage fromthe light pipe 123 to the diffuser 120 depends on the type of materialsused to fabricate the light pipe 123 and the diffuser 120, andspecifically on the indices of refractions of those materials.Additionally, in embodiments, there may be a gap between the light pipe123 and the first and second side panels 454 a and 454 b of the frame450. For example, as illustrated in FIG. 7A, the first and second sidepanels 454 a and 454 b may only come into contact with the light pipe123 at or near the lock-in wedges 216 to secure the frame 450 to thelight pipe 123. The majority of the first and second side panels 454 aand 454 b may not be in physical contact with the light pipe 123 toprevent light from leaking out of the light pipe 123. In embodiments,the latch 457 may physically couple the frame 450 to the diffuser 120 tocontrol the width of a gap between the back panel 452 of the frame 450and the light pipe 123.

FIG. 8 is top perspective view of an embodiment of the illuminationcircuit board 128 and includes similar features thereto. Theillumination circuit board 128 includes optical light sources 826 a-1 toprovide light to a diffuser and a light pipe as described herein. Thelight sources 826 a-1 may be one or more of an LED, a laser diode, anorganic LED, a black body source, or another radiation source forgenerating light. The light sources 826 a-1 are spatially configuredsuch that a subset of the light sources 826 a-1 supply optical power toone or more light pipes, and a complimentary set of the light sources826 a-1 supplies optical power to the diffuser. For example, asillustrated in FIG. 8, the four light sources 826 a-826 d are spatiallyconfigured to provide optical power to two light pipes represented bythe dotted lines around the two sets of light sources 826 a with 826 b,and 826 c with 826 d. The rest of the light sources 826 e-1 arespatially configured to provide optical power to the diffuser. Asdescribed herein, a frame physically coupled to the light pipes mayprovide a barrier between the sets of light sources providing light tothe light pipe and the light sources providing optical power to thediffuser. For example, a barrier may be present between the set of lightsources 826 a-826 b, and the set of light sources 826 i-826 j, toprevent light from the set of light sources 826 a-826 b from reachingthe diffuser, and similarly, to prevent light from the light sources 826i-826 j from reaching the light pipe.

In embodiments, the specific locations of the light sources 826 a-826 lmay be integral to generate substantially evenly distributed diffuselight from the diffuser, and to couple enough light into the light pipesto generate the direct and indirect illumination at output surfaces ofthe light pipes. In embodiments, the illumination circuit board 128 hasa central aperture 810 with a center C defined by the intersection of avertical axis V and a horizontal axis X of the circuit board 128. Thecentral aperture allows light reflected from a target object topropagate through for imaging of the target object. In embodiments, theoptical source 826 k may be at a distance of approximately 20.65 mm awayfrom the vertical axis V in a direction to the right of the verticalaxis, and a distance of 10.95 mm above the horizontal axis H, resultingin the optical source 826 k being at a radial distance of approximately23.37 mm away from the center C as illustrated in FIG. 8. Other opticallight sources may be similarly spatially configured, such as the lightsources 826 h, 826 g, and 826 l on the illumination circuit board 128 atthe same radial distance from the center C in different quadrants asdefined by the vertical and horizontal axes V and H. In embodiments, theoptical source 826 j may be at a distance of approximately 8 mm to theright of the vertical axis V, and approximately 25.35 mm above thehorizontal axis H, resulting in the optical source 826 j being a radialdistance of approximately 26.58 mm from the center C, as illustrated inFIG. 8. Similarly, optical sources, such as the light sources 826 i ,826 f, and 826 e, may be spatially configured on the illuminationcircuit board 128 at the same radial distance from the center C indifferent quadrants as defined by the vertical and horizontal axes V andH.

The light sources 826 e-826 l are the set of light sources that provideillumination to the diffuser. The number of optical light sources andthe spacing of the light sources 826 e-826 l is crucial for generating asubstantially even diffuse illumination for imaging of a target object.Additionally, in embodiments, the distance between the light sources 826e-826 l and the surfaces of the diffuser should be great enough suchthat the light is substantially diffused by the diffuser, and smallenough such that enough of the light from the light sources 826 e-826 lreaches the diffuser.

Returning to FIG. 8, in embodiments, the optical source 826 b may be ata distance of approximately 4 mm to the right of the vertical axis V,and approximately 29.7 mm above the horizontal axis H, resulting in theoptical source 826 j being a radial distance of approximately 29.97 mmfrom the center C, as illustrated in FIG. 8. Similarly, light sources,such as the light sources 826 a, 826 c, and 826 d, may be spatiallyconfigured on the illumination circuit board 128 at the same radialdistance from the center C in different quadrants as defined by thevertical and horizontal axes V and H. The light sources 826 a-826 d arethe set of light sources that provide illumination to the light pipes.The light sources 826 a and 826 b provide optical energy to a firstlight pipe, and the light sources 826 c and 826 d provide optical energyto a second light pipe. The distance from the light sources 826 a-826 dto an input surface of the light pipes is such that a majority (e.g.,greater than 50%, greater than 75% or greater than 90%) of the opticalenergy emitted by the light sources 826 a-826 d enters the light pipesthrough the input surfaces.

The illumination circuit board 128 may include other components foroperation such as electrical leads, printed bus lines, diodes,capacitors, inductors, memory, controllers, processor, amplifiers, orany other electrical components for controlling the operation of thelight sources 826 a-1.

In the foregoing specification, specific embodiments have beendescribed. However, one of ordinary skill in the art appreciates thatvarious modifications and changes can be made without departing from thescope of the invention as set forth in the claims below. Accordingly,the specification and figures are to be regarded in an illustrativerather than a restrictive sense, and all such modifications are intendedto be included within the scope of present teachings. Additionally, thedescribed embodiments/examples/implementations should not be interpretedas mutually exclusive, and should instead be understood as potentiallycombinable if such combinations are permissive in any way. In otherwords, any feature disclosed in any of the aforementionedembodiments/examples/implementations may be included in any of the otheraforementioned embodiments/examples/implementations.

The benefits, advantages, solutions to problems, and any element(s) thatmay cause any benefit, advantage, or solution to occur or become morepronounced are not to be construed as a critical, required, or essentialfeatures or elements of any or all the claims. The invention is definedsolely by the appended claims including any amendments made during thependency of this application and all equivalents of those claims asissued.

Moreover, in this document, relational terms such as first and second,top and bottom, and the like may be used solely to distinguish oneentity or action from another entity or action without necessarilyrequiring or implying any actual such relationship or order between suchentities or actions. The terms “comprises,” “comprising,” “has”,“having,” “includes”, “including,” “contains”, “containing” or any othervariation thereof, are intended to cover a non-exclusive inclusion, suchthat a process, method, article, or apparatus that comprises, has,includes, contains a list of elements does not include only thoseelements but may include other elements not expressly listed or inherentto such process, method, article, or apparatus. An element proceeded by“comprises . . . a”, “has . . . a”, “includes . . . a”, “contains . . .a” does not, without more constraints, preclude the existence ofadditional identical elements in the process, method, article, orapparatus that comprises, has, includes, contains the element. The terms“a” and “an” are defined as one or more unless explicitly statedotherwise herein. The terms “substantially”, “essentially”,“approximately”, “about” or any other version thereof, are defined asbeing close to as understood by one of ordinary skill in the art, and inone non-limiting embodiment the term is defined to be within 10%, inanother embodiment within 5%, in another embodiment within 1% and inanother embodiment within 0.5%. The term “coupled” as used herein isdefined as connected, although not necessarily directly and notnecessarily mechanically. A device or structure that is “configured” ina certain way is configured in at least that way, but may also beconfigured in ways that are not listed.

It will be appreciated that some embodiments may be comprised of one ormore generic or specialized processors (or “processing devices”) such asmicroprocessors, digital signal processors, customized processors andfield programmable gate arrays (FPGAs) and unique stored programinstructions (including both software and firmware) that control the oneor more processors to implement, in conjunction with certainnon-processor circuits, some, most, or all of the functions of themethod and/or apparatus described herein. Alternatively, some or allfunctions could be implemented by a state machine that has no storedprogram instructions, or in one or more application specific integratedcircuits (ASICs), in which each function or some combinations of certainof the functions are implemented as custom logic. Of course, acombination of the two approaches could be used.

Moreover, an embodiment can be implemented as a computer-readablestorage medium having computer readable code stored thereon forprogramming a computer (e.g., comprising a processor) to perform amethod as described and claimed herein. Examples of suchcomputer-readable storage mediums include, but are not limited to, ahard disk, a CD-ROM, an optical storage device, a magnetic storagedevice, a ROM (Read Only Memory), a PROM (Programmable Read OnlyMemory), an EPROM (Erasable Programmable Read Only Memory), an EEPROM(Electrically Erasable Programmable Read Only Memory) and a Flashmemory. Further, it is expected that one of ordinary skill,notwithstanding possibly significant effort and many design choicesmotivated by, for example, available time, current technology, andeconomic considerations, when guided by the concepts and principlesdisclosed herein will be readily capable of generating such softwareinstructions and programs and ICs with minimal experimentation.

The Abstract of the Disclosure is provided to allow the reader toquickly ascertain the nature of the technical disclosure. It issubmitted with the understanding that it will not be used to interpretor limit the scope or meaning of the claims. In addition, in theforegoing Detailed Description, it can be seen that various features aregrouped together in various embodiments for the purpose of streamliningthe disclosure. This method of disclosure is not to be interpreted asreflecting an intention that the claimed embodiments require morefeatures than are expressly recited in each claim. Rather, as thefollowing claims reflect, inventive subject matter lies in less than allfeatures of a single disclosed embodiment. Thus the following claims arehereby incorporated into the Detailed Description, with each claimstanding on its own as a separately claimed subject matter.

1. An assembly for capturing at least one image of an object appearingin an imaging field of view (FOV) the assembly comprising: a circuitboard; an imaging sensor operably coupled with the circuit board, theimaging sensor configured to capture an image frame appearing in theimaging FOV and defining an imaging axis; an illumination assemblyincluding: a plurality of light sources operably coupled with thecircuit board, the plurality of light sources configured to emit lightto illuminate the object; a diffuser positioned adjacent to theplurality of light sources, the diffuser configured to generate adiffused light pattern; and a first light pipe positioned adjacent tothe plurality of light sources to generate a direct illumination patternand an off-axis illumination pattern, wherein the direct illuminationpattern is oriented generally parallel to the imaging axis and theoff-axis illumination pattern is configured to intersect the imagingaxis, wherein the first light pipe includes: a body having a first endand a second end and defining a longitudinal light pipe axis; an inputsurface positioned at the first end of the body, the input surfaceconfigured to be positioned adjacent to, and to receive the emittedlight from, the plurality of light sources; and an exit surfacepositioned at the second end of the body extending across a width of thefirst light pipe, the exit surface including a first exit surfaceportion and a second exit surface portion, the first exit surfaceportion being oriented generally perpendicular to the imaging axis andthe second exit surface portion being oriented at an angle greater thanapproximately 85° relative to the imaging axis; wherein the longitudinallight pipe axis of the body of the first light pipe is configured to beparallel to the imaging axis and wherein the exit surface is configuredto direct the emitted light towards the object.
 2. (canceled)
 3. Theassembly of claim 1, wherein the input surface has a positive opticalpower.
 4. The assembly of claim 3, wherein the input surface includes aplurality of surfaces each having a positive optical power.
 5. Theassembly of claim 1, wherein the exit surface has a negative opticalpower.
 6. The assembly of claim 5, wherein the exit surface includes afirst exit surface portion having a concave surface and a second exitsurface portion having a convex surface being positioned adjacent to thefirst exit surface portion.
 7. The assembly of claim 6, wherein thesecond exit surface portion defines a wedge.
 8. The assembly of claim 1,wherein the diffuser includes a diffusing body and a flange portionsurrounding the diffusing body, the diffusing body having a centralregion defining an opening dimensioned to be at least equal to theimaging FOV, and the central region extending from a first height to asecond height to define a curved wall corresponding to the imaging FOV.9. The assembly of claim 8, wherein the flange portion includes a flangeopening configured to receive a portion of the first light pipe.
 10. Theassembly of claim 9, wherein the first light pipe further includes amounting member configured to operably couple the first light pipe withthe diffuser.
 11. The assembly of claim 9, wherein the imaging FOVincludes an imaging FOV width and an imaging FOV height, wherein thewidth of the first light pipe is configured to be positioned parallel tothe imaging FOV width along the flange portion of the diffuser.
 12. Theassembly of claim 11, further comprising a second light pipe positionedon the flange portion of the diffuser opposite the first light pipe. 13.The assembly of claim 11, further comprising a plurality of lightsources positioned relative to surfaces of the diffuser configured toprovide optical energy to the diffuser to generate diffuse illuminationof the object, and at least two light sources configured to provideoptical energy to the light pipe to generate direct and indirectillumination of the object.
 14. A light pipe for use in a barcode readerhaving an illumination assembly configured to illuminate at least oneobject to be captured by an imaging assembly, the light pipe including:a body having a first end and a second end and defining a longitudinallight pipe axis; an input surface positioned at the first end of thebody, the input surface configured to be positioned adjacent to andreceive emitted light from an illumination source of the imagingassembly; an exit surface positioned at the second end of the body, theexit surface including a first exit surface portion and a second exitsurface portion, the first exit surface portion being oriented generallyperpendicular to the longitudinal light pipe axis and the second exitsurface portion being oriented at an angle greater than approximately85° relative to the longitudinal light pipe axis, wherein the exitsurface is configured to direct the emitted light towards the object;wherein the body is configured to generate a direct illumination patternand an off-axis illumination pattern at the exit surface, wherein thedirect illumination pattern exits the exit surface at the first exitsurface portion and the off-axis illumination pattern exits the exitsurface at the second exit surface portion.
 15. The light pipe of claim14, wherein the light pipe is configured to transmit at approximately90% of the emitted light received at the input surface through the exitsurface.
 16. The light pipe of claim 15, wherein the exit surfaceportion is configured to transmit at least approximately 40% of theemitted light received at the input surface as direct illumination tothe object.
 17. The light pipe of claim 14, wherein the input surfacehas a positive optical power.
 18. The light pipe of claim 17, whereinthe input surface includes a plurality of converging lenses.
 19. Thelight pipe of claim 14, wherein the exit surface has a negative opticalpower.
 20. The light pipe of claim 19, wherein the first exit surfaceportion has a concave surface and the second exit surface portion has aconvex surface, and wherein the second exit surface portion ispositioned adjacent to the first exit surface portion.
 21. The lightpipe of claim 19, wherein the second exit surface portion defines awedge.
 22. The light pipe of claim 14, further including a mountingmember extending from the first end of the body, the mounting memberconfigured to engage a corresponding mounting member on an illuminationcircuit board of the illumination assembly.
 23. The light pipe of claim22, wherein the mounting member includes a locating pin. 24-41.(canceled)